Apparatus for making electrical connections



July 9, 1963 w. J. FUERTH APPARATUS FOR MAKING ELECTRICAL CONNECTIONS 3 SheetsSheet 1 Filed Dec. 19, 1960 INVENTOR.

FUERTH WILLIAM Mir/u ATTORNEYS July 9, 1963 w. J. FUERTH APPARATUS FOR MAKING ELECTRICAL CONNECTIONS NINVENTOR. J. FUERTH @m W W 4 W 5 Sheets-Sheet 2 WILLIAM BY Filed Dec.

ATTORNEYS July 9, 1963 w. J. FUERTH APPARATUS FOR MAKING ELECTRICAL CONNECTIONS Filed Dec. 19. 1960 3 Sheets-Sheet 3 INVENTOR. J. FUERTH.

W,Q 4M-W WILLIAM BY (MiE/v ATTORNEYS United States Patent 3,096,804 APPARATUS FOR MAKING ELECTRICAL CONNECTIONS William J. Fuerth, Warwick, R.I., assignor to Patton-Mac- Guyer Co., Providence, R.I., a corporation of Rhode Island Filed Dec. 19, 1960, Ser. No. 76,853 4 Claims. (Cl. 153-1) This invention relates generally to electrical contactmaking apparatus and particularly to improved apparatus for attaching electrical connectors to wire.

It has been known for some years that so-called solderless connections may be made by crimping electrical connectors to wire. Many types of crimping tools for such a purpose have been developed. Generally, all such tools provide means for deforming the ferrule of an electrical connector around a wire until a permanent set is imparted to the ferrule. This deformation creates a permanent and intimate contact between the ferrule and the wire. To accomplish the desired result, the ferrule of a connector and a wire to be joined are placed between a pair of complementary dies of appropriate size and shape and the dies are forced together until a desired degree of deformation of the ferrule and the wire results to ensure a close electrical connection. In many cases, as when connections are made in a factory, it is easy and practical to use power-driven crimping tools, by means of which satisfactory connections may be consistently made. However, when connections are to be made in the field, or when connections are to be made at a low rate in either a factory or a laboratory, it becomes impractical to use poweradriven crimping tools. It is necessary, therefore, that a manually operated crimping to'ol be provided. Known manually operated crimping tools are, in essence, modified hand pliers having special jaws shaped to be complementary dies. The wire and the ferrule to be connected together are placed between the dies and the pliers are operated manually so that the desired crimping is performed.

Several disadvantages and difficulties are experienced when known manually operated crimping tools are used. Perhaps the most important of these is that it is extremely difficult to control the amount of deformation of the ferrule to ensure uniformly good electrical connections. In other words, it is extremely diflicult consistently to o tain the proper electrical connection between the wire and ferrule using known manually operated crimping tools. Another disadvantage of known manual crimping tools is that many types of connectors, as those which are provided to the user in a long severable strip, are not well adapted to such crimping tools. 'Further, difficulty is often experienced when known manual crimping tools are to be used in restricted quarters. Finally, known manually operated crimping tools are not easily adapted to use with more than a single type of connector, in that the dies are relatively diificult to change to accommodate the tool to different types of connectors.

It is a primary object of the invention to provide a manually operated crimping tool for attaching electrical connectors to wires in such a manner that insulation piercing ears integrally formed with the body of the ferrule are forced through the insulation into electrical contact with the underlying wire. At the same time, a cutting tool attached to the movable die separates the connector being crimped from any other connectors in the crimping tool, means being provided to hold the connectors firmly in position during the cut off operation. A strip of connectors is fed intermittently through the crimping tool by means of an independently actuated feed mechanism having a movable pin automatically en- "ice gaging with successive connectors during one portion of each feed cycle and automatically disengaging therefrom during the remaining portion of each feed cycle.

Another object of the invention is to provide a manually operated crimping tool for attaching electrical connectors to wires in such a manner that insulation piercing ears integrally formed with the body of the ferrule are forced through the insulation into electrical contact with the surface of the underlying wire.

Another object of the invention is to provide a manually operated crimping tool for attaching electrical connectors to wires, the crimping tool also having means for feeding connectors sequentially into position for crimping to separate wires.

Another object of the invention is to provide a manually operated crimping tool for attaching electrical connectors to wires which is useful in many diverse environments.

Still another object of the invention is to provide a manually operated crimping tool for attaching electrical connectors to wires in which means are provided for adapting the tool to use with different types of connectors.

Other objects and many of the attendant advantages of this invention will be more readily appreciated as the invention becomes better understood by reference to the following detailed description, when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a side elevation of a manually operated crimping tool embodying the present invention;

FIG. 2 is an end elevation of the crimping tool shown in FIG. 1;

FIG. 3 is a longitudinal cross-section view taken by passing the plane 33 through FIG. 2;

FIG. 4 is a fragmentary view of the feeding mechanism, partially in phantom, showing the relationship of the parts in such mechanism during a second portion of the feeding cycle; and,

FIGS. 5 and 6 are isometric views of examples of different types of connectors which may be attached to wire in the crimping tool shown in the drawings.

Referring now to the drawings, it may be seen that the preferred embodiment of my invention comprises generally an operating section 10 and a storage reel 12 connected together by a connecting member 14. Storage assembly 12 may consist of a spindle .16 supporting and separating a pair of opposing flanges 18 (only one of which is shown) having a strip of connectors 20 spirally wound around the spindle 16 and restrained from unwanted sideways movement by the flanges 18. It is noted here that the shape of individual ones of the connectors 20 in the strip is not critical to the invention. That is, differently shaped connectors may, as, for example, the connectors shown in FIGS. 5 and 6, be used. It is necessary only that each connector have a ferrule section (preferably a substantially U-shaped element) to provide means for attaching a wire and a lug section (preferably a pierced or a forked plate) to provide means for conmeeting the completed device in an electrical circuit. The operating section 10 consists of a crimper and cut off assembly 22 mounted with a feeding assembly 24 on a common base 26.

The crimper and cut off assembly 22 consists of a pair of cooperating dies 28, 30 and associated structure to actuate such dies as will now be described. One of the dies 28 is affixed to the base 26 by any known means as by mounting screws (not shown). A relief opening 32 is formed vertically in die 28 as shown to accommodate a cut oif tool 34-, which element, in turn, is connected to the movable die 30 tomove in unison therewith. Any convenient way of fastening the cut off tool 34 to the die 30 may be used, as a pair of screws 36. I prefer to use screws 36 to connect the die 30 to an arm 38 in order that the cut off tool 34 or die '30 may be easily changed if desired. The upper end of arm 38 is con nected to a spring-retaining plate 40, as by dovetailing the two elements together and welding the same. The arm 38 is slidably mounted in a pair of opposing tracks 39 so that the upper die 30, the cut off tool 34, and the spring retaining plate 40 may slide up and down as a unit, integral with arm 38. Until such time, however, as it is desired that the die 30 move downwardly, a pawl 46 mounted on a shaft 48 is urged by a spring 50 into engagement with the lower side of the spring retaining plate 40. A driving spring 52 is disposed a retaining wall 54, the lower end of the driving spring 52 resting on the spring-retaining plate 40. The retaining wall 54 is complementary in shape to the shape of the driving spring 52 which latter element may, in a preferred em bodiment be a helix. A pair of upper elongated openings 56 (only one of which is shown) is formed through the retaining wall 54 so as to receive a compression pin 58. A second pair of opposing elongated openings (only one of which is shown) is formed in the retaining wall 54. A stub pin 62 is fitted into each of the openings 57. Two links 64 (one of which is shown in dotted outline FIG. 3) are pivotally mounted between separate ends of compression pin 58 and each one of the stub pins 62. An operating lever 66 (which preferably is bifurcated) is also pivotally connected to each of the stub pins 62. Also pivotally connected to stub pin 62 is an operating arm 68. The upper end of a connecting link 70 is pivotally mounted to a shaft '72 attached to operating arm 68 and the lower end of the connecting link 70 is formed to receive a shaft 74. A roller 76 is mounted on shaft 74. The roller 76, in turn, fits in channels (not shown) formed in the operating lever 66 so that the connecting link 70 may move longitudinally with respect to operating lever 66 and at the same time always be engaged therewith. A leaf spring 78 is disposed to bear against the underside of the operating lever 66. Thus, when the operating arm 68 is depressed, connecting link 70 forces the operating lever downwardly against leaf spring 78. At the same time, roller 76 moves longitudinally of operating lever 66 and the stub pins 62 are moved downwardly. This movement of stub pins 62 in turn causes the compression pin 58 to move downwardly to compress driving spring 52 against the spring retaining plate 40. As the operating arm 68 moves downwardly, roller 76 contacts pawl 46, causing pawl 46 to rotate around its shaft 48 and to disengage pawl 46 from spring retaining plate 40. The operating spring 52, being under compression, forces the spring-retaining plate 40 and the elements connected thereto downwardly. During the downward movement, the cut off arm 34 operates to cut off the last electrical connector in a strip of connectors, and simultaneously the upper die 30 crimps the ferrule of such severed connector around a wire to produce either of the typical connections shown in FIGS. 5 and 6. Since the details of operation of my preferred feed mechanism 24 will be described in detail hereinafter, it is suflicient here that it be understood that a wire and a connector are placed between the dies 28, 30 before the pawl 46 is released. That is, the last connector of the strip of connectors is brought into position on the lower die 28 so that its ferrule 31 opens upwardly. An end of a wire 37 is placed in the ferrule 31 so that when the upper die is forced downwardly the tapered sides thereof contact the ferrule 31 and ears 3-3 projecting therefrom to shape those elements as desired. After the operating arm 68 is released, leaf spring 78 forces the operating lever 66 upwardly, thereby returning all of the just described elements to their original position preparatory to feeding a second connector into position to be crimped.

It is noted here that the lower end of leaf spring 78 is fitted on the upper surface of a pressure pad 82, which element, in turn, is pivoted on, a pin 84. Thus, when leaf spring 78 is compressed, the pressure pad 82 is held firmly in position so that there is no chance of unwanted movement of the strip of connectors during the time the die 30 and the cut off tool 34 are in operation.

The feed mechanism 24 is shown in detail in the lower portion of FIG. 3 and also in FIG. 4. The feed mechanism consists basically of blocks 86, 88, and mounted on the base 26 and having appropriately shaped grooves (not shown) therein to accommodate a strip of the electrical connectors being processed. Blocks 88 and 90 further are recessed on their lower sides to accommodate a rocker arm 92 which is pivoted in the cavity formed between the lower sides of block 88 and block 90 and the base 26 by a pin 94. Block 88 further has a springretaining hole formed partially therethrough and opening on its lower surface to accommodate a spring 96 to urge the right-hand end of the rocker arm 92 downwardly, thus making the upper left-hand surface thereof parallel to the strip of connectors 20. A block 98, having a vertical opening formed therethrough, is placed on top of rocker arm 92 on the opposite side of the pivot pin 94 from spring 96. A beveled pin 100 is placed in the vertical opening in block 98. A transverse opening is also formed in block 98 to accommodate a connecting pin 102. Connecting pin 102 projects outwardly from block 98 through a slot 104. The outer end of connecting pin 102, in turn, is connected through link 106 to a connector advancing arm 108.

When the connector advancing arm 108 is down, or in the position shown in FIG. 1, then the link 106 operating through the connecting pin 102 forces block 98 and beveled pin 100 closer to the pivot pin 94 of the rocker arm 92. In this condition, the moment of the force tending to rotate the rocker arm 92 clockwise (which moment is a product of the distance of spring 96 from the pivot pin 94 and the strength of the spring 96) exceeds the moment of the force tending to rotate the rocker arm 92 in a counterclockwise direction. The moment tending to rotate the rocker arm 92 in a counterclockwise direction is a product of the force of [the leaf spring 78 effectively acting through the strip of connectors and the block 98. As the connector advancing arm 108 is moved in a counterclockwise direction, block 98 is forced to the left as shown in FIG. 4, increasing the moment tending to rotate the rocker arm 92 in a counterclockwise direction. Finally, the moment tending to rotate the rocker arm 92 in a counterclockwise direction exceeds the moment tending to rotate that arm in a clockwise direction, so that rocker arm 92 assumes the position shown in FIG. 4. Since the block 98' and the beveled pin 100 merely rest on the upper surface of the rocker arm 92, block 98, and beveled pin 100 move downwardly. It is noted, however, that during the time the block 98 and the beveled pin 100 are moving to the left, the beveled pin 100 is engaged in an opening in the strip of electrical conductors 'so the strip is carried along with the beveled pin 100. After the rocker arm 92 is rotated in a counterclockwise direction and the block 98 and pin 100 have moved downwardly, the pin 100 is at least partially disengaged from the opening in the strip of connectors. Thus, as the connector advancing arm 108 is moved back to its original position, beveled pin 100 is carried along with block 98 back toward the pivot pin 94, the bevel ensuring complete disengagement of the beveled pin 100' during this return movement and leaving the strip of electrical connectors in the position to which it had been moved. At the same time during the movement of the block 98 and beveled pin 100 toward the pivot 94, the moment on the rocker arm 92 causing counterclockwise rotation thereof decreases sufliciently that the rocker arm 92 moves back to its original position. Now, since the lateral movement of the block 98 and the pin 100 may be limited by proper adjustment of link 106 and the connector advancing arm 108, then the reciprocal motion of t e beveled pin 100 may be made to be the same as the distance between successive openings in the strip of electrical connectors. Thus, after moving the connectors a fixed distance to the left, the beveled pin 100 moves back into position so that it can pick up the next opening in the strip.

A pressure pad release is also provided whereby the pressure pad 82 may be moved upwardly while connectors are being threaded into the crimping tool. The pressure pad release consists of an operating knob 110 supported near the bottom of the crimping tool in the wall thereof and connected to a shaft 111 (shown in dotted lines in FIG. 3 and FIG. 4). An eccentric pin 112 fitting loosely into an opening in pressure pad 82 is attached to shaft 111. Thus, when the operating knob 110* is turned, the pressure pad 82 is caused to rotate against the leaf spring 78 around pivot point 84, thereby making it possible to raise the end of the pressure pad 82 which normally engages the electrical connectors being processed so that a strip of such connectors may be easily fed into the tool.

It will be noted that the dies 28, 30 may be easily changed as desired to crimp electrical connectors diifering from the type illustrated merely by removing the mounting screws 36 and replacing the dies being used with other dies. Further, the device may be easily modified to compensate for connectors having differently spaced openings therein merely by adjusting the length of either the link 106 or the distance between the pivot point of the operating arm 108 and the point of connection of link 106 to such operating arm.

Obviously, many modifications and variations of this invention other than those noted above are possible in the light of the above teachings. It is to be understood, therefore, that the invention is not limited in its application to the details of construction and the arrangement of parts specifically described or illustrated, and that within the scope of the appended claims, it may be practiced otherwise than as specifically described or illustrated.

I claim:

1. In apparatus for uniformly making a crimped connection between a wire and the end one of similar electrical connectors in a strip thereof, each one of said electrical connectors including a ferrule section and a lug section, an intermittent feeding and holding assembly for said strip, comprising: a base adapted to receive a portion of said strip; a rocker arm pivotally mounted on said base below said portion of said strip and having a surface parallel to said portion; a restraining spring disposed between said base and said rocker arm to exert a fixed moment of force on said rocker arm; a block slidably mounted between said portion of said strip and said surface, a transverse and a vertical opening being formed in said block; a connecting link disposed in said transverse opening and projecting outwardly therefrom; a pin slidably mounted in said vertical opening and projecting upwardly there from, the lower end of said pin resting on said surface and the upper end engaging a lug section of one of said electrical connectors; a pressure pad pivotally mounted on said base and bearing on the upper surface of said portion of said strip; a pressure pad spring bearing on said pressure pad whereby the moment of force of said restraining spring initially is balanced by a moment of force acting through said pressure pad, said portion of said strip and said block; means attached to the outer end of said connecting link to move said block along said surface to move said portion of said strip and simultaneously to increase the moment of said force from said pressure pad to cause said rocker arm to rotate to disengage said pin from said lug section; and means to increase the force of said pressure pad spring to hold said portion of said electrical connectors in place during the crimping operation.

2. Apparatus for uniformly making a 'crimped connection between an electrical connector having a U-shaped ferrule consisting of a body portion and opposing ears formed integrally therewith and an electrical conductor having a resilient insulating covering thereon, comprising, a crimping die having a fixed anvil and a movable section, feeding means for placing and holding the rounded portion of the body portion of said electrical connector in said fixed anvil to receive an end of said electrical conductor, means springily operated to move said movable section into contact with the sides of said body portion and said opposing ears, whereby said body portion is crimped to said insulating covering and said ears are recurved therethrough into contact with the surface of said electrical conductor, a portion of said resilient insulating covering being compressed between one surface of each one of said ears and a surface of said body portion of said ferrule whereby an intimate contact is maintained between said electrical conductor and each one of said ears; said electrical connector being the last one of a strip of similar connectors and said feeding means includes a spring-loaded rocker arm having one surface thereof initially parallel to said strip, a pin slidably mounted on said one surface and initially engaging said strip, a pressure pad springily urging said strip toward said rocker arm and means for moving said pin along said one Surface to move said strip whereby said electrical connector to be crimped is placed in said fixed anvil and said rocker arm is caused to rotate to disengage said pin from said strip.

3. Apparatus as in claim 2 having, in addition, a cut off tool affixed to saidmovable section of saidcrimping die whereby said electrical connector to be crimped is separated from said strip during the time said movable section is in contact with said electrical connector to be crimped, and means for increasing the pressure on said strip through said pressure pad to hold said strip in position relative to said out off tool during the time said cut oif tool is in contact with said strip.

4. Apparatus for uniformly making a crimped connection between a wire and the end one of a strip of electrical connectors; each one of said connectors including a ferrule section and a lug section; said apparatus comprising storage means for holding said strip; a spring-actuated movable crimping die and a stationary lower die; a cut ofi tool affixed to said movable die; feeding means adapted to shift said strip and position a ferrule of said end one of said electrical connectors beneath said crimping die; said feeding means intermittently cooperating with successive lug sections of the electrical connectors; means simultaneously actuating said feeding means, said spring actuated die and said out off tool whereby said ferrule is crimped to said wire and severed from the supply strip; said feeding means including a rocker arm adjacent one side of said strip; said rocker am having an initial and a second position; a surface of said rocker arm being parallel to said strip when said rocker arm is in said initial position; means, including a first spring urging said rocker arm into its said initial position; a pin slidably mounted on said one surface and engaging a lug section of one said electrical connectors in said strip; a pressure pad contacting the second side of said strip; a block slidably mounted on said one surface and contacting said one surface of said strip; means, including a second spring urging said pressure pad into contact with said strip, whereby a force urging said rocker arm into its said second position is applied through said pressure plate, said strip and said block; and, means simultaneously moving said block and said pin along said one surface whereby said strip is moved and said rocker arm is rotated into its said second position to disengage said pin.

References Cited in the file of this patent UNITED STATES PATENTS 917,739 Owens Apr. 6, 1909 2,832,410 Soss Apr. 29, 1958 2,842,018 Hammell et al. July 8, 1958 2,850,093 DAngel o et Sept. 2, 1958 

2. APPARATUS FOR UNIFORMLY MAKING A CRIMPED CONNECTION BETWEN AN ELECTRICAL CONNECTOR HAVING A U-SHAPED FERRULE CONSISTING OF A BODY PORTION AND OPPOSING EARS FORMED INTEGRALLY THEREWITH AND AN ELECTRICAL CONDUCTOR HAVING A RESILIENT INSULATING COVERING THEREON, COMPRISING, A CRIMPING DIE HAVING A FIXED ANVIL AND A MOVABLE SECTION, FEEDING MEANS FOR PLACING AND HOLDING THE ROUNDED PORTION OF THE BODY PORTION OF SAID ELECTRICAL CONNECTOR IN SAID FIXED ANVIL TO RECEIVE AN END OF SAID ELECTRICAL CONDUCTOR, MEANS SPRINGLY OPERATED TO MOVE SAID MOVABLE SECTION INTO CONTACT WITH THE SIDES OF SAID BODY PORTION AND SAID OPPOSING EARS, WHEREBY SAID BODY PORTION IS CRIMPED TO SAID INSULATING COVERING AND SAID EARS ARE RECURVED THERETHROUGH INTO CONTACT WITH THE SURFACE OF SAID ELECTRICAL CONDUCTOR, A PORTION OF SAID RESILIENT INSULATING COVERING BEING COMPRESSED BETWEEN ONE SURFACE OF EACH ONE OF SAID EARS AND A SURFACE OF SAID BODY PORTION OF SAID FERRULE WHEREBY AN INTIMATE CONTACT IS MAINTAINED BETWEEN SAID ELECTRICAL CONDUCTOR AND EACH ONE OF SAID EARS; SAID ELECTRICAL CONNECTOR BEING THE LAST ONE OF STRIP OF SIMILAR CONNECTORS AND SAID FEEDING MEANS INCLUDES A SPRING-LOADED ROCKER ARM HAVING ONE SURFACE THEREOF INITIALLY PARALLEL TO SAID STRIP, A PIN SLIDABLY MOUNTED ON SAID ONE SURFACE AND INITIALLY ENGAGING SAID STRIP, A PRESSURE PAD SPRINGILY URGING SAID STRIP TOWARD SAID ROCKER ARM AND MEANS FOR MOVING SAID PIN ALONG SAID ONE SURFACE TO MOVE SAID STRIP WHEREBY SAID ELECTRICAL CONNECTOR TO BE CRIMPED IS PLACED IN SAID FIXED ANVIL AND SAID ROCKER ARM IS CAUSED TO ROTATE TO DISENGAGE SAID PIN FROM SAID STRIP. 